Ford 4x4 2002 explorer will not go into 4 wheel drive

jackwmssr wrote:
I think I need the help of a Ford mechanic. My 2002 ford explorer 4.0 v6 automatic will not shift into any 4x4 positions. I have checked all the fuses that I can find, 1 under the dash and 2 under the hood. It does not make any sounds at all when I push the 4x4 buttons. It did not make any strange sounds the last I used it a few weeks ago. I have tried it moving and sitting still, in neutral with the brake on. I have had it since new and used it every winter so I am sure it is not operator error. It has 99000 miles on it. Now for a little recent history. I had the cables disconnected to clean the post 3 weeks ago. Two days later I used a homeowner style alternator tester to check the alternator (good). I jumped the MH last week to start it, all of these since the last time used the 4x4. While doing the above I never did hook any thing up wrong. THE FORECAST IS CALLING FOR SNOW tonight 7 to 9 inches. I would be very thankful if some one can help me with this.

dlk wrote:
First off is it the shift on the fly 4x4, if it is you can try this, don't ask me how I know. On the transfer case, drivers side is an electronic servo motor that shifts the unit from 4 hi or low, mine used to not work at times, I took a rubber mallet and gave it a couple of whacks and guess what it worked again, your out nothing but a few minutes of time to see if it works.

Sloop Smitten wrote:
What Dan indicated is a well known problem with the transfer case shift servo. It rotates to the end of play where they installed nylon bushings that get crushed over time. When that happens the servo loses its place and you have to remove it and reposition the internal components. If you do a search on any of the online Explorer forums they have it pretty well documented. I had to do it on my old Explorer as well. You might check the plug at the servo as well and make sure it has not been damaged or disconnected.